Why Automation Systems Demand Control Power Protection

Control power protection makes or breaks automation systems.

Picture this: Your production line grinds to a halt. Circuit boards fail. Deadlines slip away.

The cost?

A staggering $39 billion in annual losses across American industries, all from unprotected electronic loads.

When control power fails, your entire operation stops. No slowdown. No warning. Just silence.

This manufacturing nightmare becomes reality for facilities without proper protection.

As The Power Grid Podcast host Brian Branigan explains, control power protection isn’t optional; it’s essential for survival in industrial automation.

 

Understanding Control Power Vulnerabilities

At the heart of most industrial processes lie large 480-volt motors controlled by low-voltage circuits.

This voltage step-down creates a perfect storm for power surges:

• Power surges can travel from a single leg of 480-volt power
• They pass through step-down transformers
• Finally, they directly impact sensitive control circuits

“Control power surge protection will protect the circuit boards from these internally generated power surges,” explains Branigan, drawing from almost 30 years of solving power quality problems.

The Hidden Threats to Your Systems

Power surges in industrial settings come from everyday operations like load switching, short circuits, and capacitor switching. Even common equipment such as variable speed drives, arc welders, and motor starters can generate dangerous surges.

These 480-volt level disturbances can infiltrate and damage critical circuit boards that control your systems.

 

Critical Systems at Risk

Modern facilities rely heavily on low-voltage control power across their operations. From essential instrumentation systems and water treatment controls to HVAC systems and manufacturing equipment, these sensitive components form the backbone of your facility.

Medical equipment, testing systems, and programmable logic controllers (PLCs) are particularly vulnerable to power disruptions.

Protecting Your Investment: Control Power Protection Solutions

Today’s control power protection technology offers comprehensive safeguards through two main approaches.

First, fixed clamping technology utilizes metal oxide varistors and sine wave tracking systems to provide robust surge protection.

Second, EMI/RFI filtering systems, certified to UL 1449 fifth edition and UL 1283 seventh edition standards, ensure complete protection against electrical disturbances.

The Code Compliance Factor

Recent National Electrical Code (NEC) updates emphasize the importance of control power protection:

NEC 695.15:

• Requires listed surge protection devices for fire pump controllers
• Protects against surges generated by the fire pump itself

NEC 700.8:

• Mandates surge protection for emergency system switchboards and panels
• Ensures reliable operation of critical safety systems

NEC 409.7 D:

• Requires surge protection for personal protection safety circuits
• Must be installed within or adjacent to control panels

NEC 670.6:

• Mandates surge protection for industrial machinery safety interlocks
• Prevents disabled safety mechanisms from endangering operators

Real-World Impact: The Sock Factory Case Study

Branigan shares a compelling story from an Iowa sock factory that highlights the importance of comprehensive protection:

“Lightning struck the building, and despite having surge protection at the electrical service entrance, the let-through voltage reached the knitting machines’ control power systems. The result? Severe downtime, product waste, and costly circuit board replacements.”

This case demonstrates why layered protection, from service entrance to control power level, is essential for complete system security.

Implementation Strategies

Effective control power protection can be implemented in several ways:

• Series or parallel installation from the load side of step-down transformers
• Din rail mounting inside control cabinets
• Strategic placement near sensitive equipment
• Integration with existing surge protection systems

Powering Your Protection Strategy

Modern automation demands more than equipment protection, control power protection keeps operations running, maintains safety standards, and protects your bottom line.

Don’t wait for a catastrophic failure to highlight the importance of control power protection.

Take action now to safeguard your systems, protect your investments, and maintain uninterrupted facility operations.

Protect Your Production Power Today

For nearly three decades, P3 has solved power quality challenges across America’s critical facilities. We bring superior expertise to control power protection, data centers, and custom power solutions.

Ready to protect your facility’s control power systems?

Our team creates solutions that work – no complexity, just results.

Contact us at 877-393-1223 or visit P3-Inc.com to learn more.

 

 

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Powerful Insights: Your Control Power Protection Questions Answered

What is control power protection?

Control power protection involves specialized surge protection devices designed to safeguard low-voltage control circuits that manage industrial equipment and automation systems from power surges and electrical disturbances.

Why is control power protection necessary?

It prevents costly downtime, protects sensitive electronic equipment, and ensures safety systems remain operational. Without it, facilities risk equipment damage, production losses, and safety hazards.

What types of facilities need control power protection?

Any facility using automated equipment, PLCs, or sensitive electronic controls needs protection. This includes manufacturing plants, water treatment facilities, hospitals, and industrial complexes.

How does control power protection work?

It uses various technologies like metal oxide varistors, sine wave tracking, and EMI/RFI filtering to prevent harmful power surges from reaching sensitive control circuits.

What are the latest code requirements for control power protection?

Recent NEC updates require surge protection for fire pump controllers (695.15), emergency systems (700.8), safety circuits (409.7 D), and industrial machinery safety interlocks (670.6).

Can I install control power protection if I already have surge protection?

Yes, and it’s recommended. Layered protection ensures comprehensive coverage, as upstream surge protectors may still allow potentially harmful let-through voltage.

Where should control power protection be installed?

Protection should be installed at the load side of step-down transformers, inside control cabinets, or adjacent to sensitive equipment, depending on your specific needs.

How do I know what type of control power protection I need?

The type of protection needed depends on your specific voltage requirements, equipment sensitivity, and application. A professional assessment can determine the best solution for your facility.

What are the signs that I need control power protection?

Frequent equipment failures, unexplained downtime, circuit board damage, or operation in an environment with numerous motor starts/stops are all indicators.

How does control power protection contribute to workplace safety?

It ensures the reliable operation of safety interlocks, emergency systems, and protective equipment, helping maintain a safe working environment and compliance with safety regulations.